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INDEX GENERAL INFORMATION PERIODIC INSPECTION AND ADJUSTMENT CHASSIS POWER TRAIN ENGINE OVERHAUL CARBURETION ELECTRICAL APPENDICES

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APPX


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ILLUSTRATED SYMBOLS

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(Refer to the illustration) Illustrated symbols Q) to ® are designed as thumb tabs to indicate the chapter's number and content.

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Q) General information @

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Periodic inspection and adjustment Chassis Power train Engine Carburetion Electrical Appendices

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Illustrated symbols ® to ® are used to identify the specifications which appear.

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Filling fluid Lubricant Tightening Wear limit, clearance Engine speed Q,V,A

Illustrated symbols @ to ® in the exploded diagrams indicate the grade of lubricant and the location of lubrication points.

@ @ @ @ @)

®

Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply low-temperature lithium-soap base grease Apply wheel bearing grease (Esso-Beacon 325 grease or Aero Shell grease #7) Apply molybdenum disulfide grease

Illustrated symbols ® to @ in the exploded diagrams indicate the grade of sealing or locking agent and the location of application points.

®

Apply locking agent (LOCTITE®)

@ Apply Yamabond No. 4® @ Apply Yamabond No.5®


_______________ I~1=~I..1 CHAPTER 1. GENERAL INFORMATION MACHINE IDENTIFICATION ............................. 1-1 FRAME SERIAL NUMBER ........................... 1-1 ENGINE SERIAL NUMBER ......................... 1-1 IMPORTANT INFORMATION ........................... 1-2 ALL REPLACEMENT PARTS ....................... 1-2 GASKETS, OIL SEALS, AND a-RINGS ...... 1-2 BEARINGS AND OIL SEALS ....................... 1-2 CIRCLlPS ...................................................... 1-2 SPECIAL TOOLS ............................................... 1-3 FOR TUNE UP .............................................. 1-3 FOR ENGINE SERVICE ................................ 1-4 FOR POWER TRAIN SERVICE .................... 1-4 FOR ELECTRICAL SERVICE ........................ 1-6


MACHINE IDENTIFICATION

----

I~EF~ I~I

GENERAL INFORMATION MACHINE IDENTIFICATION FRAME SERIAL NUMBER The frame serial number CD is located on the right-hand side of the frame (just below the front of the seat).

ENGINE SERIAL NUMBER (Primary I.D.l The engine serial number CD is located on the right-hand side of the crankcase. NOTE: _________________________ The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Starting Serial Number VT480R ........................ 88T-000101

NOTE: ______________________ Designs and specifications are subject to change without notice.

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IMPORTANT INFORMATION

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IMPORTANT INFORMATION ALL REPLACEMENT PARTS 1. We recommend the use of Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS 1. All gaskets, seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

BEARINGS AND OIL SEALS 1. Install the bearing(s) CD and oil seal(s) <ID with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

300-002

Do not use compressed air to spin the bearings dry. This causes damage to the surface of the bearings.

300-003

CIRCLlPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace misshapen circlips. When installing a circlip CD , make sure that the sharp edged corner <ID is positioned opposite the thrust ÂŽ it receives. See the sectional view. 300-001

@ Shaft

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SPECIAL TOOLS

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SPECIAL TOOLS Some special tools are necessary for complete accurate tune-up and assembly. Using the correct special tool will help prevent damage that can be caused by the use of improper tools or improvised techniques.

NOTE: ________________________ Be sure to use the correct part number when ordering the tool, since the part number differs according to the destination as shown below. The first part number is for Europe and the other number is for the U.S.A. and Canada. e.g. 90890-****, YU-****

FORTUNE UP 1. Vacuum Gauge @P/N YS-33275 ÂŽSealing Plug PIN YU-91035-3 (2 required) This tool is used for carburetor synchronization.

2. Sheave Gauge PIN 90890-01702, YS-91047 This gauge is used to measure sheave distance and for offset adjustment.

3. Dial Gauge P/N-90890-03097, YU-03097 This gauge is used for ignition timing adjustment.

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SPECIAL TOOLS

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FOR ENGINE SERVICE 1. Piston Pin Puller P/N-90890-01304, YU-01304 This tool is used to remove the piston pin.

2. Universal Rotor Holder P/N-90890-01235, YU-01235 This tool is used to hold the CDI magneto.

3. Rotor Puller P/N-90890-01362, YU-33270 This tool is used to remove the magneto rotor.

FOR POWER TRAIN SERVICE 1. Primary Sheave Holder P/N-90890-01701, YU-01880 This tool is used to hold the primary sheave.

2. Primary Sheave Puller (18 mm) P/N-90890-01898, YS-01882-A This tool is used for removing the primary

sheave.

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SPECIAL TOOLS

I~EF~ lA!!I

3. Sheave Compressor P/N-90890-01712, YS-28891 This tool is used when disassembling and assembling the sheave.

4. Clutch Spider Separator P/N-90890-01711, YS-28890-B This tools are used when disassembling and assembling the primary sheave.

5. Clutch Separator Adapter P/N-90890-01740, YS-34480 This tool is used when disassembling and assembling the primary sheave.

6. Eccentric Bearing Installer P/N-90890-01721, YS-91 045 This tool is used when removing and installing the front axle.

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SPECIAL TOOLS

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FOR ELECTRICAL SERVICE 1. Pocket Tester P/N-90890-03112, YU-03112 This instrument is necessary for checking the electrical components.

2. Electra Tester P/N-90890-03021, YU-33260 This instrument is used to check the electrical system.

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_________~I ... I CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ................................................ 2-1 PERIODIC MAINTENANCE TABLE ................... 2-1 ENGINE .............................................................. 2-3 SPARK PLUG ............................................... 2-3 FUEL FILTER INSPECTION ......................... 2-3 FUEL LINE INSPECTION ............................. 2-4 ENGINE OIL LINE INSPECTION ................. 2-4 THROTTLE OVERRIDE SYSTEM (T.O.R.S.) CHECK ........................................................ 2-5 THROTTLE CABLE FREE PLAY ADJUSTMENT ........................................... 2-5 CARBURETOR SYNCHRONIZATION ......... 2-6 ENGINE IDLE SPEED ADJUSTMENT ........ 2-8 EXHAUST SYSTEM .................................... 2-9 STARTER CABLE FREE PLAY ADJUSTMENT ........................................... 2-9 OIL PUMP .................................................. 2-10 COOLING FAN BELT ................................. 2-11 COOLING FAN BELT TENSION ADJUSTMENT ......................................... 2-12 SHEAVE DISTANCE AND OFFSET ADJUSTMENT ......................................... 2-13 POWER TRAIN ................................................. 2-16 DRIVE V-BELT ............................................ 2-16 ENGAGEMENT SPEED CHECK ................ 2-18 BRAKE PAD INSPECTION ........................ 2-18 BRAKE ADJUSTMENT .............................. 2-19 DRIVE CHAIN HOUSING OIL LEVEL INSPECTION ............................................ 2-19 DRIVE CHAIN TENSION ADJUSTMENT ......................................... 2-20 TRACK TENSION ADJUSTMENT ............ 2-21 SLIDE RUNNER INSPECTION .................. 2-23 CHASSIS .......................................................... 2-23 SKI/SKI RUNNER ....................................... 2-23 STEERING SYSTEM .................................. 2-23 SKI ADJUSTMENT .................................... 2-24 HANDLEBAR ADJUSTMENT ................... 2-25 LUBRICATION ........................................... 2-26

ELECTRICAL .................................................... 2-27 HEADLIGHT BULB REPLACEMENT ......... 2-27 HEADLIGHT BEAM ADJUSTMENT ......... 2-28 TAIL/BRAKE LIGHT BULB REPLACEMENT ....................................... 2-28 BATTERY INSPECTION ............................ 2-28 FUSE INSPECTION ................................... 2-30 TUNING ........................................................... 2-32 CARBURETOR TUNING ............................ 2-32 CLUTCH TUNING ...................................... 2-40 GEARING SELECTION .............................. 2-41 HIGH ALTITUDE TUNING ......................... 2-43 SLIDE RAIL SUSPENSION TURNING ...... 2-44


INTRODUCTION/IINSP PERIODIC MAINTENANCE TABLE

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PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all ofthe information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable machine operation and a longer service life. In addition, the need for costly overhaul work will be greatly reduced. This information applies to machines already in service as well as new machines that are being prepared for sale. All service technicians should be familiar with this entire chapter.

PERIODIC MAINTENANCE TABLE

No.

Item

Remarks

Spark Plug

2

Engine Oil

3

Fuel

Check fuel level.

4

*Fuel Filter

Check condition. Replace if necessary.

S

*Fuel Line

Check fuel hose for cracks or damage. Replace if necessary.

6

*Oil Line

Check oil hose for cracks or damage. Replace if necessary.

Check oil level. *Air bleed the oil pump if necessary.

Check throttle lever operation. Carburetor

8

*Fan Belt

First Month or first 800 km (500 Mi) (40 hr)

Check condition, adjust the gap and clean. Replace if necessary.

1

7

Preoperation check (Daily)

• • •

• • • •

Whenever operating conditions (elevation/temperature) are changed.

*Adjust the jets.

• •

Check wear and damage. Replace if necessary. Adjust fan belt if necessary.

Manual Starter

Check operation and rope damage. *Replace if necessary.

10

Engine Stop Switch

Check operation *Repair if necessary.

11

Throttle Override System

Check operation. *Repair if necessary.

12

Throttle Lever

Check operation. *Repair if necessary.

13

*Exhaust System

14

*Decarbonization

9

Every Season or 3,200 km (2,000 Mi) (160 hr)

• • • •

Check for leakage. Retighten or replace gasket if necessary. More frequently if necessary.

15

Drive V-belt Guard

Check for cracks, bending or damage. *Replace if necessary.

16

Drive V-belt

Check wear and damage. Replace if necessary.

• •

• •

*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic. **: Perform after 1 Month or 50 Km (31 Mi) (2 hr) and every 1 Month or 400 Km (250 Mi).

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PERIODIC MAINTENANCE TABLE

No.

Remarks

Item

17

Drive Track/Idler Wheels

18

Slide Runner

19

Brake/ Parking Brake

20

*Drive Chain Oil

21

*Drive Chain

22

Ski/Ski Runner

Check for deflection, wear and damage. *Adjust/replace if necessary. Check for wear and damage. *Replace if necessary. Check operation. *Adjust free play and/or replace pads if necessary.

First Month or first 800 km (500 Mi) (40 hr)

**.

• • •

Check oil level. Replace.

**.

Check for deflection. Adjust if necessary. Check for wear and damage. *Replace if necessary. Check operation.

23

Steering System

24

Lights

Check operation. Replace bulbs if necessary.

Battery

*Check specific gravity and breather pipe operation. Charge/Correct if necessary.

*Adjust toe-out if necessary.

Check fluid level. 25

Preoperation check (Daily)

Ir~ 1-.1

• • •

Adjust if necessary. *Primary Sheave

• • • •

• •

• • • • • • • • • •

Check engagement and shift speed. 26

Every Season or 3,200 km (2,000 Mi) (160hr)

Whenever operating elevation is changed.

Check for wear and damage. Replace if necessary. Lubricate with specified grease. Lubricate with specified grease.

27

*Secondary Sheave

28

*Steering Column Bearing

29

*Ski and Front Suspen- Lubricate with specified grease. sion

30

*Suspention Component

Lubricate with specified grease.

*Brake Cable End and Lever EndIThrottle Cable End

Lubricate with specified grease.

31

Adjust if necessary.

Whenever operating elevation is changed.

Lubricate with specified grease.

Check for cable damage. Replace if necessary.

32

Shroud Latches

Make sure the shroud latches are hooked.

33

Fittings/Fasteners

Check tightness. *Repair if necessary.

34

Service Tools/Spare Parts

Check proper placement.

• • •

*: It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic. **: Perform after 1 Month or 50 Km (31 Mi) and every month or 400 Km (250 Mi).

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SPARK PLUG/FUEL FILTER INSPECTION

1r&.r 1_I

ENGINE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode CD Wear/Damage

~

Replace.

• Insulator color ® 3. Measure: • Plug gap@ Out of specification ~ Regap. Use a Wire Gauge of Feeler Gauge. Spark plug gap: 0.7 - 0.8 mm (0.028 - 0.032 in)

Clean the plug with a spark plug cleaner if necessary.

Standard spark plug: BR9ES (NGK) Before installing a spark plug, clean the gasket surface and plug surface.

4. Tighten: • Spark plug Spark plug: 28 Nm (2.8 m • kg, 20 ft • Ib)

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NOTE: ________________________ Finger-tightenCDthe spark plug before torquing ® to specification.

377-004

FUEL FILTER INSPECTION 1. Remove: • Seat 2. Disconnect: • Tail/Brake light coupler

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FUEL LINE INSPECTION/ENGINE OIL LINE INSPECTION 3. Remove: • Spring bands • Cap® • Fuel filter ®

Ir~ 1.1

CD

4. Inspect: • Fuel filter CD Contamination

---+

Replace.

Recommended replacement interval: Every season

FUEL LINE INSPECTION 1. Inspect: • Fuel hoses • Fuel delivery hoses Cracks/Damage ---+ Replace.

ENGINE OIL LINE INSPECTION 1. Inspect: • Oil hoses CD • Oil delivery hoses ® Cracks/Damage ---+ Replace.

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1991 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Manual  

1991 YAMAHA VENTURE VT480 SNOWMOBILE Service Repair Manual  

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